Drive assembly for a modular conveyor

ABSTRACT

A modular conveying assembly including a plurality of modules joined together, each module including a bushing housing, a coupling housed in the bushing housing, an axle coupled to the coupling and supported for rotation relative to the module, a drive pin coupled to the coupling, and a driven surface fixed to the drive pin. The modular conveying assembly also including a driving member that is in selective engagement with the driven surface to affect rotation of the axle.

RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.16/506,021 filed on Jul. 9, 2019, which is a continuation of U.S. patentapplication Ser. No. 16/307,008 filed on Dec. 4, 2018, now U.S. Pat. No.10,392,192 issued on Aug. 27, 2019, which represents the national stageentry of PCT International Application No. PCT/US2017/036091 filed onJun. 6, 2017, which claims priority to U.S. Provisional PatentApplication No. 62/347,326 filed on Jun. 8, 2016, the entire contents ofwhich are incorporated herein by reference as if set forth in theirentirety.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH

Not Applicable.

BACKGROUND

The invention relates generally to modular conveyor belts and chains,and more particularly to an active control roller top conveyor moduleand a modular conveying assembly including at least one of the conveyormodules.

Modular conveyors include modules connected together to form a belt orchain that is supported by a frame and driven to transport a product.Each module has a support surface that supports the product as thebelting or chain is driven along the frame. Adjacent modules areconnected to each other by hinge pins inserted through hinge membersextending from adjacent modules in the direction of the belt travel.

SUMMARY

Modular belts can transport products in the direction of conveyortravel, but have difficulty accumulating a product without introducinghigh backline pressure. In addition, high levels of friction typicallyexist between the modular belt and the products during accumulation. Oneknown solution to this problem is to rotatably mount rollers directly onthe hinge pin connecting modules together, such that the hinge pinsupports the rollers between hinge members. The roller rotates about anaxis of rotation that is substantially coaxial with the hinge pin axis.Because it is beneficial to have a portion of the roller extend abovethe module to engage the object being conveyed to reduce backlinepressure, the roller diameter is related to the hinge pin location andthe height of the module. Unfortunately, this often results in requiringa large diameter roller that extends both above and below the moduleeven when that configuration is not always desired. Moreover, supportingthe roller on the pin alone can result in undesirable pin wear.

Rexnord Industries, LLC of Milwaukee, Wis. developed roller topconveying modules that include roller axle supports that supportfreewheeling rollers above a module top surface; illustrated, forexample, in: U.S. Pat. Nos. 8,151,978; 5,096,050; 4,880,107; and4,821,169. These modules are easily assembled and do not requireoversize rollers extending through the conveyor modules. Also, thesemodules allow accumulation of product being conveyed by a conveyingsystem formed from modules by providing a low backline pressure when theproducts are stopped on the moving modules. Absent individual externalstops for each product being conveyed, the conveyed products engageother products when accumulating on the conveyor system.

Additionally, Rexnord Industries, LLC of Milwaukee, Wis. developedactive control roller modules that further reduce product-to-productcontact during accumulating and product manipulation, such as shown inU.S. Pat. No. 9,227,785.

Embodiments provide a modular conveying assembly with active rollercontrol for reducing backline pressure without product-to-productcontact during accumulation. The conveying assembly includes a firstroller belt module having a top surface and at least one first rolleraxle support extending above the top surface. At least one roller issupported above the top surface by the first roller axle support. The atleast one roller is rotatably coupled to a drive axle such that rotationof the drive axle causes rotation of the roller. A clutch includes adriven surface fixed to the drive axle, and a driving member that isengageable with the driven surface to rotatably drive the drive axle andthe roller.

In the detailed description below, preferred embodiments will bedescribed in reference to the accompanying drawings. These embodimentsdo not represent the full scope of the invention. Rather, the inventionmay be employed in other embodiments. Reference should therefore be madeto the claims herein for interpreting the breadth of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a pictorial view of a modular conveying assembly including adriving member and supporting a package.

FIG. 2 is a left side view of the modular conveying assembly of FIG. 1.

FIG. 3 is a front view of the modular conveying assembly of FIG. 1.

FIG. 4 is a detail view of a portion of a belt module of the modularconveying assembly of FIG. 1.

FIG. 5 is an exploded view showing the belt module of FIG. 4.

FIG. 6 is a pictorial view of a coupling.

FIG. 7 is a pictorial view of a drive pin.

FIG. 8 is a pictorial view of an alternative drive pin.

FIG. 9 is a cross-sectional view of the belt module taken along the line9-9 in FIG. 5.

FIG. 10 is a cross-sectional view of the assembly taken along the line10-10 in FIG. 4.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

As shown in FIG. 1, a modular conveying assembly, or continuous belt 24includes a plurality of belt modules 28 assembled in an edge-to-edgeconfiguration. Hinge pins 32 (see FIG. 2) join adjacent belt modules 28,and pivotally connect the adjacent belt modules 28 in a direction ofbelt travel 36 (see FIG. 4). Each belt module 28 includes roller axlesupports 40 that extend upwardly from a module body 44 of each beltmodule 28 and support a roller axle 48 (see FIG. 4) having a pluralityof rollers 52 fixed thereto. The roller axle supports 40 extend upwardlyfrom leading edge hinge members 56 and trailing edge hinge members 60(see FIG. 3). The rollers 52 rotatably engage an object 64 beingconveyed by the continuous belt 24 to reduce friction between thecontinuous belt 24 and the object 64, and selectively convey the object64 relative to the module body 44 in a direction of belt travel 36. Thebelt modules 28 can be formed by injection molding from materials suchas acetal, polyethylene, polypropylene, or nylon. Each belt module 28 ofthe continuous belt 24 also includes a bushing housing 68, a coupling 72(see FIG. 4), a drive pin 76, and a clutch 80 that includes a drivensurface 84 and a driving member 88.

As shown in FIG. 2, each leading edge hinge member 56 includes anopening 92 for receiving the hinge pin 32. Each leading edge hingemember opening 92 receives one hinge pin 32 and pivotally connects theleading edge hinge members 56 of one belt module 28 to trailing edgehinge members 60 of an upstream belt module 28. The trailing edge hingemembers 60 include openings 94 that receive the hinge pin 32 topivotally connect the trailing edge hinge members 60 of the belt module28 to leading edge hinge members 56 of a downstream belt module 28.

As shown in FIG. 4, the roller axle supports 40 are spaced across themodule body 44 in a row transverse to the direction of belt travel 36(see FIG. 1). Each roller axle support 40 includes a coaxial supportopening 96 for receiving the roller axle 48. Advantageously, the axlesupports 40 do not allow the roller axle 48 to pop upwardly away fromthe belt modules 28 if the roller 52 or roller axle 48 catches an object64. Although six axle supports 40 in a single row on each belt module 28are shown, a single axle support 40 extending upwardly from the modulebody 44 forming a row or a plurality of axle support 40 rows on a singlebelt module 28 can be provided.

As further shown in FIG. 4, the rollers 52 support the object 64 beingconveyed by the continuous belt 24 above the module body 44 and arerotatably fixed to the roller axle 48. At least a portion of each roller52 extends above the roller axle supports 40 to engage the object 64being conveyed by the continuous belt 24. Preferably, each roller 52 ismolded from a plastic, and includes a through hole 100 (see FIG. 5)formed there through for receiving the roller axle 48. The rollers 52can be rotatably fixed to the roller axle 48 by chemically bonding theroller 52 to the roller axle 48, fusing the roller 52 to the roller axle48, integrally forming the roller axle 48 and roller 52 as a singlepiece, forming a through hole 100 (see FIG. 10) axially through theroller 52 and inserting the roller axle 48 through the roller throughhole 100, or the like. Although a plastic roller 52 is disclosed, theroller 52 can be formed from any material, such as elastomers, metals,and the like, suitable for the particular application. In oneembodiment, rollers 52 may be end connected to one another by teeth. Inanother embodiment rollers 52 may be end connected to one another bymagnets. These connections between rollers 52 provide a way to transferrotation without rigidly joining the rollers 52 to the roller axle 48.Other configurations are contemplated for coupling the rollers 52together independent of the roller axle 48. For example, couplings,taper locks, and other connection types are usable.

As shown in FIG. 5, the bushing housing 68 of each belt module 28extends upward from the module body 44 of the belt module 28 and definesa bushing housing aperture 104. The bushing housing 68 allows the rolleraxle 48 to rotate. The bushing housing 68 can inhibit vibration of theroller axle 48.

The roller axle 48 can be formed from any material, such as a polymericmaterial or metal. Polymeric roller axles 48 are generally preferredbecause they typically are lighter and produce less noise. Each rolleraxle 48 supports rollers 52. Preferably, a single roller 52 is disposedbetween a pair of axle supports 40, however, more than one roller 52 canbe provided between a pair of axle supports 40. In one embodiment, theroller axle 48 may define a spline shape, a keyway, or a D-shape.Additionally, the roller axle 48 may define other shapes (e.g., square,oval, pegged, star, etc.).

As shown in FIG. 6, the coupling 72 includes a cylindrical tubestructure having a wall thickness sufficient for bearing rotationalloads. The coupling tube structure includes an outer surface 108 sizedto be rotationally received within the bushing housing aperture 104 anda coupling mating feature in the form of a splined coupling aperture 112sized to receive the roller axle 48. In other embodiments, the couplingmating feature can be on the outside surface of the coupling tubestructure or define a different profile. For example, the couplingmating feature can include a barbed connection, a keyed connection, orother connection as desired. The coupling 72 also includes a shoulder116 that extends radially outward from the outer surface 108substantially perpendicular to an axis of rotation 120, and a projection122 (see FIG. 9) that extends into the splined coupling aperture 112.

As shown in FIG. 7, the drive pin 76 includes a drive pin mating featurein the form of a drive pin shaft 124, a first shoulder 128, a secondshoulder 132, and a coupling in the form of a barbed shaft 136. Thedrive pin shaft 124 is splined to match the splined coupling aperture112 and includes a recess 140 sized to engage the projection 122.Although the drive pin shaft 124 is shown in FIG. 7, it is to beappreciated that the drive pin mating feature can include a variety ofgeometries and mating forms, such as, for example, a keyway or aD-shape. The first shoulder 128 and the second shoulder 132 extendradially outward substantially perpendicular to the axis of rotation120. As shown in FIG. 7, the second shoulder 132 can extend furtheroutward than the first shoulder 128

As shown in FIG. 8, an alternative embodiment of a drive pin 76′includes a drive pin mating feature in the form of a drive pin shaft124′, a shoulder 132′, and a driven surface in the form of a magneticplate or rotor 144. The drive pin shaft 124′ includes a recess 140′sized to engage the projection 122. The rotor 144 can be formed from aferris material or other magnetically-active material and defines arotor width 148 and a rotor diameter 152. A spacer shaft 156 is disposedbetween the rotor 144 and the shoulder 132′.

As shown in FIG. 10, each belt module 28 is assembled by inserting thebarbed shaft 136 of the drive pin 76 into the driven surface 84. In theembodiment shown in FIG. 10, the driven surface 84 is frustoconicalshaped and formed from rubber. The barbed shaft 136 engages the drivensurface 84 and rotation between the drive pin 76 and the driven surface84 is inhibited.

The coupling 72 is then inserted into the bushing housing aperture 104such that the outer surface 108 rotationally engages the bushing housingaperture 104 and the shoulder 116 abuts the bushing housing 68. With thecoupling 72 installed in the bushing housing 68, the drive pin 76 isinserted into the coupling 72 such that the drive pin shaft 124 engagesthe splined coupling aperture 112 and the projection 122 is receivedwithin the recess 140. The engagement of the projection 122 and therecess 140 inhibits the removal of the drive pin 76 from the coupling72. The second shoulder 132 is arranged adjacent the bushing housing 68when the drive pin 76 is fully installed into the coupling 72.

The rollers 52 are then placed in there respective spaces between theaxle supports 40 and the roller axle 48 is inserted through the coaxialsupport openings 96, the roller through holes 100, and into the splinedcoupling aperture 112. With the roller axle 48 installed, the drivensurface 84, the drive pin 76, the coupling 72, the roller axle 48, andthe rollers 52 are rotationally locked together to provide rotationabout the axis of rotation 120.

In one embodiment, the drive pin 76 is male and the coupling 72 isfemale. In this embodiment, the drive pin 76 is inserted into thecoupling 72, and the coupling mating feature on the inner surface of thecoupling 72 engages with the drive pin mating feature on the outersurface of the drive pin 76. In another embodiment, the drive pin 76 isfemale and the coupling 72 is male. In this embodiment, the drive pin 76is pushed around the coupling 72, and the coupling mating surface on theouter surface of the coupling 72 engages with the drive pin matingfeature on the inner surface of the drive pin 76.

The continuous belt 24 is assembled by intermeshing the trailing edgehinge members 60 of one of the belt modules 28 with the leading edgehinge members 56 of the adjacent belt module 28, such that the trailinghinge member openings 94 of the one belt module 28 are aligned with theleading edge hinge member openings 92 of the other belt module 28. Hingepins 32 are then slipped through the aligned hinge member openings topivotally link the adjacent belt modules 28 together. The linking ofmultiple belt modules 28 creates the continuous belt 24.

In operation, the clutch 80 is actuated by selective engagement of thedriving member 88 and the driven surface 84. In the embodiment shown inFIG. 1, the driving member 88 is a rod arranged to contact an upperportion of the driven surfaces 84. When the continuous belt 24 is movingin the direction of belt travel 36, and the driving member 88 is broughtinto engagement with the driven surfaces 84, the driven surfaces 84 arecounter rotated relative to the direction of belt travel 36 and in turncause the counter rotation of the drive pin 76. This counter rotation inturn translates to the roller 52, and the rollers 52 act on the object64 to produce an accumulation effect where the continuous belt 24continues to progress in the direction of belt travel 36 but the object64 is maintained in an accumulation zone.

Alternatively, the clutch 80 can be arranged such that the drivingmember 88 engages a bottom portion of the driven surfaces 84 andproduces an accelerating effect on the object 64. Further, multiplemotion zones can be established to produce motion profiles includingrotation, left or right movement, directional accumulation, directionalacceleration, slowing, and other motion profiles, as desired.

The driving member 88 may be actuated vertically or horizontally in andout of engagement with the driven surface 84. Any actuation scheme maybe used to bring the driving member 88 into contact with the drivensurface 84, as desired.

In another embodiment, a clutch 80′ includes a magnetic driving member88′ in the form of electromagnets or permanent magnets, and the drivepin 76′ including the rotor 144. The driving member 88′ is arranged toproduce a magnetic eddy within the rotor 144 that will produce forwardor counter rotation of the rollers 52 and produce a desired motionprofile. Alternatively, the rotors 144 could include magnets or bemagnetic themselves. The rotor width 148 and rotor diameter 152 affectthe resultant force of the magnetic coupling between the driving member88′ and the rotor 144.

While there has been shown and described what are at present consideredthe preferred embodiments of the invention, it will be obvious to thoseskilled in the art that various changes and modifications can be madetherein without departing from the scope of the invention defined by theappended claims. For example, the individual features described in thedrawings may include one or more features from another embodiment.

We claim:
 1. A module for use in a modular conveying assembly, themodule comprising: a bushing housing extending from a first end to asecond end; a coupling having a first shoulder and defining a firstmating feature; and a drive pin having a second shoulder and defining asecond mating feature; wherein the first shoulder of the coupling isadjacent to the first end of the busing housing; wherein the secondshoulder of the drive pin is adjacent to the second end of the businghousing; and wherein the first mating feature and the second matingfeature are configured to axially couple the coupling and the drive pinto the busing housing positioned between the first shoulder and thesecond shoulder.
 2. The module of claim 1, wherein: the first matingfeature comprises one of a projection and a recess; and the secondmating feature comprises the other one of the one of the projection andthe recess.
 3. The module of claim 1, wherein: the first shoulderextends radially outward from an outer coupling surface of the couplingin a direction that is perpendicular to an axis along the coupling; andthe second shoulder extends radially outward from an outer drive surfaceof the drive pin in a direction that is perpendicular to an axis alongthe drive pin.
 4. The module of claim 1, further comprising a drivensurface fixed to the drive pin, the driven surface configured to beselectively engaged to affect rotation of the drive pin and thecoupling.
 5. The module of claim 1, wherein: the coupling defines asplined aperture; the drive pin defines a splined drive pin shaft; andthe splined aperture and the splined drive pin shaft are configured torotatably couple the coupling and the drive pin.
 6. A coupling assemblyconfigured for use with a belt module including a bushing housing and aroller axle, the coupling assembly comprising: a coupling configured tobe rotatably fixed to the roller axle and defining a first matingfeature; and a drive pin defining a second mating feature; wherein atleast a portion of the coupling and at least a portion of the drive pinare configured to be housed within the bushing housing; and wherein thefirst mating feature and the second mating feature are configured toaxially couple the coupling and the drive pin.
 7. The coupling assemblyof claim 6, wherein: the first mating feature comprises one of aprojection and a recess; and the second mating feature comprises theother one of the one of the projection and the recess.
 8. The couplingassembly of claim 6, wherein: the coupling defines a male counterpartwith the first mating feature configured on an outer surface of the malecounterpart; and the drive pin defines a female counterpart with thesecond mating feature configured on an inner surface of the femalecounterpart.
 9. The coupling assembly of claim 6, wherein the firstmating feature and the second mating feature axially capture the bushinghousing between the coupling and the drive pin.
 10. The couplingassembly of claim 6, wherein: the coupling defines a first shoulder; thedrive pin defines a second shoulder; and the first shoulder is adjacentto a first end of the bushing housing and the second shoulder isadjacent to a second end of the busing housing to inhibit axial movementof the coupling and the drive pin relative to the bushing housing. 11.The coupling assembly of claim 6, further comprising a driven surfacefixed to the drive pin, the driven surface configured to be selectivelyengaged to affect rotation of the roller axle.
 12. A coupling assemblyconfigured for use with a belt module, the coupling assembly comprising:a coupling extending from a first coupling end to a second coupling end;a first mating feature of the coupling at a first position between thefirst coupling end and the second coupling end; a drive pin extendingfrom a first drive pin end to a second drive pin end; a second matingfeature of the drive pin at a second position between the first drivepin end and the second drive pin end; and a shoulder extending from thedrive pin; and wherein the first mating feature and the second matingfeature are configured to axially couple the coupling and the drive pin;and wherein the first position of the first mating feature and thesecond position of the second mating feature are configured such thatthe shoulder of the drive pin is positioned adjacent to at least one ofthe second coupling end of the coupling and a bushing housing withinwhich at least one of the coupling and drive pin are at least partiallyhoused.
 13. A coupling assembly configured for use with a belt module,the coupling assembly comprising: a coupling extending from a firstcoupling end to a second coupling end; a first mating feature of thecoupling at a first position between the first coupling end and thesecond coupling end; a drive pin extending from a first drive pin end toa second drive pin end; a second mating feature of the drive pin at asecond position between the first drive pin end and the second drive pinend; and a shoulder extending from the drive pin; and wherein the firstmating feature and the second mating feature are configured to axiallycouple the coupling and the drive pin; and wherein the first position ofthe first mating feature and the second position of the second matingfeature are configured such that the shoulder of the drive pin ispositioned adjacent to an end face of the belt module.
 14. A couplingassembly configured for use with a belt module, the coupling assemblycomprising: a coupling extending from a first coupling end to a secondcoupling end, the coupling defines a coupling aperture formed betweenthe first coupling end and the second coupling end; a first matingfeature of the coupling at a first position between the first couplingend and the second coupling end, the first mating feature defines arecess formed in the coupling aperture; a drive pin extending from afirst drive pin end to a second drive pin end, the drive pin defines anouter surface; and a second mating feature of the drive pin at a secondposition between the first drive pin end and the second drive pin end,the second mating feature defines a projection formed in the outersurface; and wherein the first mating feature and the second matingfeature are configured to axially couple the coupling and the drive pin.15. A coupling assembly configured for use with a belt, the couplingassembly comprising: a coupling extending from a first coupling end to asecond coupling end; a first mating feature of the coupling at a firstposition between the first coupling end and the second coupling end; adrive pin extending from a first drive pin end to a second drive pinend; and a second mating feature of the drive pin at a second positionbetween the first drive pin end and the second drive pin end; andwherein the first mating feature and the second mating feature areconfigured to axially couple the coupling and the drive pin; wherein thecoupling defines a male counterpart with the first mating featureconfigured on an outer surface of the male counterpart; and wherein thedrive pin defines a female counterpart with the second mating featureconfigured on an inner surface of the female counterpart.
 16. A couplingconfigured for use with a belt module including a roller axle and adrive pin, the coupling comprising: a body extending from a firstcoupling end to a second coupling end; a roller axle mating featureproximate to the first end and configured to rotatably couple to theroller axle; and a first drive pin mating feature between the firstcoupling end and the second coupling end and configured to axiallycouple to a second drive pin mating feature defined by the drive pin;wherein the first drive pin mating feature includes one of a radialrecess and a radial protrusion; and wherein the second drive pin matingfeatures includes the other of the one of the radial recess and theradial protrusion.
 17. The coupling of claim 16, wherein the bodydefines a splined coupling aperture.
 18. The coupling of claim 16,wherein: the coupling defines a coupling aperture that extends betweenthe first coupling end and the second coupling end; the roller axledefines an axle end that is inserted into the coupling apertureproximate the first coupling end to rotatably fix the roller axle andthe coupling; and the drive pin defines a drive pin end that is insertedinto the coupling aperture proximate the second coupling end torotatably fix the drive pin and the coupling.
 19. A coupling configuredfor use with a belt module including a roller axle and a drive pin, thecoupling comprising: a body extending from a first coupling end to asecond coupling end; a roller axle mating feature proximate to the firstend and configured to rotatably couple to the roller axle; and a firstdrive pin mating feature between the first coupling end and the secondcoupling end and configured to axially couple to a second drive pinmating feature defined by the drive pin; and wherein the drive pindefines a shoulder that is spaced along the drive pin from the seconddrive pin mating feature such that the shoulder is adjacent to a side ofthe belt module when the second drive pin mating feature and the firstdrive pin mating feature are axially coupled.